Systems and methods of manufacturing a brazing alloy component

ABSTRACT

Systems and methods of manufacturing a brazing alloy component such that the brazing alloy component has sufficient ductility to be formed into a ring-shaped member.

TECHNICAL FIELD

Systems and methods are provided for manufacturing brazing alloycomponents, and particularly to manufacturing brazing alloy componentshaving sufficient ductility to form a ring-shaped member.

BACKGROUND

Conventional systems and methods for manufacturing alloys used to brazeferrous and non-ferrous metals and alloys have been successful for manyyears. However, while such conventional methods provide techniques formanufacturing brazing alloys, these systems and methods have notprovided brazing alloys capable of forming ring-shaped members to beused in various brazing applications.

SUMMARY

In accordance with one embodiment, a method for manufacturing a brazingalloy component comprises extruding a billet to form an elongatedmember, drawing the elongated member through a die mechanism, andcooling the elongated member to form the alloy component. The billetcomprises an alloy material consisting essentially of phosphorus,silicon, copper and at least one of tin and antimony. The alloycomponent is sufficiently ductile such that the alloy component can beformed into a ring-shaped member.

In accordance with another embodiment, a method of manufacturing abrazing alloy component comprises means for extruding a billet to forman elongated member, means for drawing the elongated member through adie, means for cooling the elongated member to form an alloy component,and means for forming a ring-shaped member from the alloy component. Thebillet comprises an alloy material consisting essentially of phosphorus,silicon, copper and at least one of tin and antimony.

In accordance with yet another embodiment, a system of manufacturing abrazing alloy component comprises an extrusion device, a heatingmechanism, a drawing device and a cooling mechanism. The extrusiondevice is configured to extrude a billet to form an elongated member.The billet comprises an alloy material consisting essentially ofphosphorus, silicon, copper and at least one of tin and antimony. Theelongated member has a predetermined thickness. The heating mechanism isconfigured to heat the elongated member having exited the extrusiondevice. The drawing device is configured to receive the elongated memberfrom the heating mechanism and modify the elongated member. The modifiedelongated member has a smaller thickness than the predeterminedthickness. The cooling mechanism is configured to cool the elongatedmember exiting the drawing device to form an alloy component.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the same willbe better understood from the following description taken in conjunctionwith the accompanying in which:

FIG. 1 illustrates a process flow diagram of a system for manufacturingalloy components;

FIG. 2A illustrates a side elevational view of an extruder die;

FIG. 2B illustrates a cross-sectional view of the extruder die takenalong section lines 2B-2B in FIG. 2A;

FIG. 3 illustrates an embodiment of drawing and annealing stations;

FIG. 4 illustrates a cross-sectional view of an embodiment of a drawingdie;

FIG. 5A illustrates a side elevational view of a ring-shaped memberformed from an alloy component; and

FIG. 5B illustrates an end view of the ring-shaped member of FIG. 5A.

DETAILED DESCRIPTION

Embodiments are herein described in detail in connection with thedrawings of FIGS. 1-5, wherein like numbers indicate the same orcorresponding elements throughout the drawings.

As illustrated in the embodiment of FIG. 1, a system 10 is shown ashaving multiple production stations in which to produce an alloycomponent 11 for use in brazing applications. In the embodiment of thesystem 10 generally illustrated in FIG. 1, the system 10 produces analloy component 11 having enhanced ductility characteristics. In someembodiments, the ductility characteristics of the alloy component can beenhanced to such an extent that the alloy component 11 can be formedinto the shape of rings. As shown in FIG. 1, the manufacturing system 10can comprise multiple stages or stations. For example, the system 10 caninclude an extrusion station 12, drawing station 14, annealing station16 and preform station 18, as shown in FIG. 1. At the extrusion station12, a billet 15 composed of an alloy material enters a heating mechanism20 and then passes through an extruder device 22, as shown in FIG. 1.The extruder device 22 extrudes the billet from a given shape andgenerally forms an elongated member generally in the shape of a rod orwire. The extruder device generally includes extruder dies (e.g., item24 of FIG. 2). The extruder die is the component of the extruder devicethrough which the billet is forced, thus producing the elongated memberwhich ultimately forms into the alloy component. In one embodiment theextruder device can include one extruder die. In another embodiment, theextrude device can include multiple extruder dies.

Extruder dies can have any of a variety of suitable designs. Oneembodiment of an extruder die 24 is illustrated in FIGS. 2A and 2B. Asshown in FIGS. 2A and 2B, the extruder die 24 includes a bore 26 whichpasses from an inlet side 28 of the extruder die 24 to an outlet side 30of the extruder die 24. As illustrated in FIG. 2B, the diameter of thebore 26 decreases as the bore 26 passes through the extruder die 24 fromthe inlet side 28 to the outlet side 30. As more clearly shown in FIGS.2A and 2B, the extruder die 24 has a ram surface 31, which includes thatsurface of the extruder die 24 on the inlet side 28. The number ofextruder dies used for the process can vary. In one embodiment, thenumber of extruder dies can vary based upon the ram surface area of oneextruder die versus the total surface area of the extruder die.

Once the extruded elongated member exits the extruder device 22, it canbe cooled prior to entering the drawing station 14. For example, theextruded elongated member can be placed on rolls to cool prior to beingsent to the drawing station 14. The drawing station 14, as generallyrepresented in FIG. 1, is placed downstream from the extrusion station12 such that the drawing station 14 can utilize a drawing device 32 tofurther manipulate the elongated member to form the alloy component 11,so that the alloy component 11 can be drawn down to a smaller, moredesired shape or size. For example, the thickness of the elongatedmember as it exits the extruder device 22 may be larger than isultimately desired, and the drawing device 32 can modify the thicknessof the elongated member so that the proper thickness can be achieved forthe alloy component 11 being formed.

One embodiment of a drawing station 14 is illustrated in FIG. 3. Asshown in FIG. 3, the drawing station 14 includes a heating mechanism 34and a drawing device 32. The heating mechanism 34 can include a tank 36which includes a heated substance 38 (e.g., oil or lubricant), as shownin the embodiment of FIG. 3. In one embodiment, the elongated member canpass from the extrusion station 12 (see FIG. 1) to an intermediatestation, for example, a payoff device (e.g., roller 33 in FIG. 3) priorto entering the drawing station 14. However, in an alternativeembodiment, the elongated member can pass directly to the drawingstation 14 from the extrusion station 12. As shown in FIG. 3, theelongated member leaves a roller 33 and enters the drawing station 14.

The elongated member can be heated by the heating mechanism 34 prior toentering the drawing device 32. This step softens the elongated memberso that it can more easily be drawn down into a desired size or shape.The drawing device 32, as shown in FIG. 3, can include one or moredrawing dies 40. One embodiment of such a drawing die is illustrated as40 in FIG. 4). The drawing die 40 shown in FIG. 4 includes an inlet 42,an outlet 44 and a bore 50. The inlet 42 generally has a larger openingthan the outlet 44, as shown in the embodiment of FIG. 4. Such anarrangement provides the capability of the drawing device 32 to reducethe diameter or thickness of the elongated member in a controlled manneras the elongated member passes through the drawing device 32. Theembodiment of FIG. 4 illustrates a narrowing of the opening of the bore50 as the bore 50 passes through the drawing die 40 from the inlet 42 tothe outlet 44. The wall 46 defining the bore 50 in the drawing die 40has various changes in its surface as the wall 46 passes from the inlet42 to the outlet 44. These surface changes in the wall 46 can furtherassist in controlling the change in the diameter/thickness of theelongated member as it passes through the drawing die 40 on its way toforming the alloy component 11.

Once the elongated member is drawn down through the drawing station 14,it enters an annealing station 16 as shown in the embodiments of FIGS. 1and 3. At the annealing station 16, the elongated member can be cooledby a cooling mechanism 48 which can set the alloy component 11. Thiscooling mechanism can take on various forms. In one embodiment asgenerally illustrated in FIG. 3, the cooling mechanism 48 can include ahigh pressure water sprayer 49 which dissipates the heat associated withthe elongated member as it exits the drawing device 32 and allows thealloy component 11 to set into its final form. It is contemplated thatthe cooling mechanism can take on other forms such as a freezer or asprayer which uses a coolant other than water to dissipate the heatassociated with the wire or rod as it exits the drawing station.

As shown in the embodiment of FIG. 1, once the alloy component 11 exitsthe annealing station 16, the alloy component 11 (e.g., wire or rod) canbe modified at a preform station 18. In one embodiment, the preformstation includes a machine for mechanically manipulating the alloycomponent from the shape of a wire or rod into a ring-shaped member. Asshown in the embodiment of FIGS. 5A and 5B, a ring-shaped member 52 caninclude a gap 54, wherein the gap 54 is defined by a first end 56 and asecond end 58 of the alloy component. Numerous designs of such ringforming machines exist today, and it is contemplated that any suchdesigns that are available in the marketplace can be utilized in apreform station such that the alloy component can be made into aring-shaped member which can then be used for brazing applicationsassociated with various applications as discussed below. In oneembodiment, the ring-shaped member can have a thickness, “T”, asrepresented in FIG. 5A, ranging from about 0.039 inches to about 0.125inches. In one embodiment, the ring-shaped member can have an innerdiameter, “ID”, as represented in FIG. 5A, ranging from about 0.20inches to about 10.0 inches. In another embodiment, the ring-shapedmember can have an inner diameter or outer diameter that is 0.007 inchesover or under the outer diameter or inner diameter, respectively, of atube or fitting on which the ring-shaped member will be used for abrazing application. Examples of ring-shaped members having variousthicknesses and inner diameters are provided below.

EXAMPLES Example 1

Wire thickness—0.070 inchesRing inner diameter—0.308 inches

Example 2

Wire thickness—0.070 inchesRing inner diameter—0.366 inches

Example 3

Wire thickness—0.070 inchesRing inner diameter—0.369 inches

The process described herein provides an alloy component with enhancedductility characteristics, and in fact, provides an alloy component withsuch increased ductility that the alloy component can be formed intoring-shaped members as discussed above. The alloy component discussedherein has a liquidus temperature above about 840° F., thus making thering-shaped members formed from the alloy component suitable for brazingapplications. In fact, one embodiment of the alloy component includesthe component having a brazing temperature below about 1300° F. Inanother embodiment, the alloy component has a brazing temperature belowabout 1250° F.

As noted herein, prior to the extrusion of the alloy component, thealloy material is in the form of a billet. A billet can comprisemultiple forms (e.g., block or cylinder). The billet can be cast from amelting process whereby the chemical elements used to make the alloymaterial are added together. In one embodiment, the alloy material inits broadest form consists essentially of phosphorus, silicon, copperand at least one of tin and antimony. In another embodiment, the alloyconsists essentially of from about 6.0% to about 7.0% phosphorus, fromabout 6.5% to about 7.0% tin and/or antimony, from about 0.005% to about0.4% silicon and the remainder copper. In yet another embodiment, thealloy consists essentially of from about 6.5% to about 6.7% phosphorus,from about 6.65% to about 6.85% tin and/or antimony, from about 0.01% toabout 0.2% silicon and the remainder copper. In another embodiment, thealloy consists essentially of about 6.6% phosphorus, about 6.75% tinand/or antimony, about 0.015% silicon and the remainder copper. It isnoted, that impurities may be present by virtue of the raw materialsused to manufacture the alloys or due to process conditions, and are tobe distinguished from elements intentionally added to the alloy. Thus,the embodiments of the alloy materials described herein may includeimpurity amounts of other elements. While the alloy material can includeother chemical elements, one embodiment contemplates having the alloycomponent formed substantially of only the elements phosphorus, tin,silicon and copper. It is noted that, in an alternative embodiment, tincould be replaced with or used in conjunction with antimony. Moreover, abenefit of adding silicon in the presence of tin is to provide a colorand/or texture change of the copper base from a dull, grainy, brownfinish to a very smooth finish and/or bright tin color. Silicon added tothe alloy can also increase the average tensile strength of copperalloys.

In accordance with one embodiment, the ring-shaped member 52 can beplaced between two metal or alloy parts and then heated such that atleast a major portion of the alloy material from the ring-shaped member52 is molten such that it flows between the two metal or alloy parts. Itis contemplated that the ring-shaped member can be coated with a fluxmaterial which can be mechanically added to the ring-shaped memberduring manufacture or manually added subsequent to production. It willbe appreciated that the flux can facilitate improved flow and bonding ofthe molten alloy material. Once cooled, a brazen joint is formed,wherein the material of the ring-shaped member 52 is bonded to the twometal components. When the alloy component is in the form of aring-shaped member, it can be used in applications where the parts to bejoined are substantially tubular in shape.

Other advantages to using systems, methods and alloy components asdescribed herein can be more broadly contemplated as well. For example,the alloy component provides a low melting temperature, providesstrength and gives good capillary fill on loose joints and still workseffectively on tight joints.

The foregoing description of embodiments and examples has been presentedfor purposes of illustration and description. It is not intended to beexhaustive or to limit the invention to the forms described. Numerousmodifications are possible in light of the above teachings. Some ofthose modifications have been discussed, and others will be understoodby those skilled in the art. The embodiments were chosen and describedin order to best illustrate various embodiments as are suited to theparticular use contemplated. It is hereby intended that the scope of theinvention be defined by the claims appended hereto.

1. A method for manufacturing a brazing alloy component, the methodcomprising: extruding a billet to form an elongated member, the billetcomprising an alloy material consisting essentially of phosphorus,silicon, copper and at least one of tin and antimony; drawing theelongated member through a die mechanism; and cooling the elongatedmember to form an alloy component, wherein the alloy component issufficiently ductile such that the alloy component can be formed into aring-shaped member.
 2. The method of claim 1, further comprising forminga ring-shaped member from the alloy component.
 3. The method of claim 1,wherein the alloy component is in the form of a rod or a wire.
 4. Themethod of claim 2, wherein the ring-shaped member has an inner diameterranging from about 0.308 inches to about 0.369 inches.
 5. The method ofclaim 1, wherein the alloy material comprises from about 6.0% to about7.0% phosphorus, from about 6.5% to about 7.0% tin, from about 0.005% toabout 0.4% silicon, and the remainder copper.
 6. The method of claim 5,wherein the alloy material comprises from about 6.5% to about 6.7%phosphorus, from about 6.65% to about 6.85% tin, from about 0.01% toabout 0.2% silicon, and the remainder copper.
 7. The method of claim 6,wherein the alloy material comprises about 6.6% phosphorus, about 6.75%tin, about 0.015% silicon, and the remainder copper.
 8. The method ofclaim 1, wherein the step of cooling the elongated member comprisescontacting the elongated member with water.
 9. The method of claim 8,wherein the water contacts the elongated member under a pressurizedstate.
 10. The method of claim 1, further comprising dividing the alloycomponent into a plurality of sections.
 11. An alloy componentsufficiently ductile to form a ring-shaped member, wherein the alloycomponent is manufactured from the method of claim
 1. 12. The alloycomponent of claim 11 comprising a ring-shaped member.
 13. A method ofmanufacturing a brazing alloy component, the method comprising: meansfor extruding a billet to form an elongated member, wherein the billetcomprises an alloy material consisting essentially of phosphorus,silicon, copper and at least one of tin and antimony; means for drawingthe elongated member through a die; means for cooling the elongatedmember to form an alloy component; and means for forming a ring-shapedmember from the alloy component.
 14. A system of manufacturing a brazingalloy component, the system comprising: an extrusion device configuredto extrude a billet to form an elongated member, wherein the billetcomprises an alloy material consisting essentially of phosphorus,silicon, copper and at least one of tin and antimony, and wherein theelongated member has a predetermined thickness; a heating mechanismconfigured to heat the elongated member exiting the extrusion device; adrawing device configured to receive the elongated member from theheating mechanism and modify the elongated member, wherein the modifiedelongated member has a smaller thickness than the predeterminedthickness; and a cooling mechanism configured to cool the elongatedmember having exited the drawing device to form an alloy component. 15.The system of claim 14, wherein the system further comprises a preformmachine configured to form the alloy component into a ring-shapedmember.
 16. The system of claim 14, wherein the alloy material comprisesfrom about 6.0% to about 7.0% phosphorus, from about 6.5% to about 7.0%tin, from about 0.005% to about 0.4% silicon, and the remainder copper.17. The system of claim 14, wherein the heating mechanism comprisesheating oil.
 18. The system of claim 14, wherein the extrusion deviceincludes at least one extruder die.
 19. The system of claim 15, whereinthe ring-shaped member has an inner diameter ranging from about 0.20inches to about 10.0 inches.
 20. The system of claim 15, wherein thering-shaped member has a thickness ranging from about 0.039 inches toabout 0.125 inches.